Using a suitable belt tensioner release tool, rotate the accessory drive belt tensioner clockwise and position the accessory drive belt aside from the generator pulley.

Remove the 2 outer generator bracket bolts.

Remove the 2 lower generator nuts.

Disconnect the generator electrical connector and pin-type retainers.

Position the B+ terminal cover aside and remove the B+ terminal nut. Remove the generator.

Install the Engine Lifting Brackets.

If equipped, remove the 4 nuts and the strut tower cross brace.

Install the Engine Support Bar.

NOTE

Both the RH and LH engine support insulator nuts must be removed to allow the engine to be raised.

Remove the RH and LH engine support insulator nuts.

Using the Engine Support Bar, raise the engine 1.57 inch (40 mm).

NOTE

Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).

Using a suitable holding device, hold the steering wheel in the straight-ahead position.

NOTE

Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered.

Remove the bolt and disconnect the steering coupling. Discard the bolt.

Remove the 4 bolts and the LH engine support insulator bracket.

Remove the 8 nuts and the exhaust manifold. Discard the nuts and gaskets.

Clean and inspect the LH exhaust manifold.

Remove and discard the 8 LH exhaust manifold studs.

NOTE

Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered.

Connect the steering coupling and install the new bolt. Tighten to 18 ft. lbs. (25 Nm).

Using a suitable belt tensioner release tool, rotate the accessory drive belt tensioner clockwise and position the accessory drive belt aside from the generator pulley.

Remove the 2 outer generator bracket bolts.

Remove the 2 lower generator nuts.

Disconnect the generator electrical connector and pin-type retainers.

Position the B+ terminal cover aside and remove the B+ terminal nut. Remove the generator.

Install the Engine Lifting Brackets.

If equipped, remove the 4 nuts and the strut tower cross brace.

Install the Engine Support Bar.

NOTE

Both the RH and LH engine support insulator nuts must be removed to allow the engine to be raised.

Remove the RH and LH engine support insulator nuts.

Using the Engine Support Bar, raise the engine 1.57 inch (40 mm).

Remove the nut and the ground wire from the stud bolt.

If equipped, remove the nut and position aside the transmission cooler tube bracket.

Remove the 2 bolts, 2 stud bolts and the RH engine support bracket.

Remove the 8 nuts and the exhaust manifold. Discard the nuts and gaskets.

Clean and inspect the RH exhaust manifold.

Remove and discard the 8 RH exhaust manifold studs.

NOTE

Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).

Using a suitable holding device, hold the steering wheel in the straight-ahead position.

NOTE

Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered.

Remove the upper bolt from the intermediate steering shaft and position the intermediate steering shaft aside.

Fig. Removing the upper bolt from the intermediate steering shaft and positioning the intermediate shaft aside

Remove the 8 nuts and the LH exhaust manifold. Discard the nuts and gaskets.

Clean and inspect the LH exhaust manifold.

Remove and discard the 8 LH exhaust manifold studs.

Fig. Exploded view of the LH exhaust manifold (1 of 2) (5.4L Engine)

Fig. Exploded view of the LH exhaust manifold (2 of 2) (5.4L Engine)

To install:

NOTE

Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

Install new gaskets, the LH exhaust manifold and 8 new nuts. Tighten in the sequence shown to 177 inch lbs. (20 Nm).

NOTE

Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered.

The heavy duty Engine Support Bar (303-F070) must be used with the draw screws from the light duty Engine Support Bar (303-F072). This will provide enough clearance between the SC and the Engine Support Bar, and enough clearance between the draw screw and the vehicle hood.

Install the Engine Support Bars.

Remove the RH engine support insulator nut.

Using the Engine Support Bars, raise the RH side of the engine.

Fig. Installing the engine support bars

Remove the SC drive belt from the A/C compressor pulley.

Remove the wiring harness retainers from the A/C compressor stud bolts and position the wiring harness aside.

NOTE

The A/C compressor stud bolts must be loosened to gain access to the RH exhaust manifold nuts.

Loosen the A/C compressor stud bolts 0.98 inch (25 mm).

Remove the 8 nuts and the RH exhaust manifold. Discard the nuts and gaskets.

Clean and inspect the RH exhaust manifold.

Remove and discard the 8 RH exhaust manifold studs.

Fig. Exploded view of the RH exhaust manifold

Installation

NOTE

Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.